Spray-Drying Process for Low-Density Detergent Powder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing spray-drying process for laundry detergent powder production is inefficient in capturing nitrogen-rich gas bubbles, leading to high-density powders and requiring large volumes of expensive nitrogen-rich gas for low-density production.
Innovation Solution
Introducing nitrogen-rich gas between the first and second pumps in the spray-drying process, where the liquid detergent ingredient is contacted with the aqueous detergent slurry, enhances the entrapment efficiency of gas bubbles, resulting in lower density detergent powders at reduced gas usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nitrogen-rich gas is injected into the high pressure pipe between the high pressure pump and the spray nozzle, then the spray-dried powder density is reduced, but the gas consumption increases significantly and entrapment efficiency is low
Solution Approach 1:
The nitrogen-rich gas is injected into the slurry between the first and second pumps, before the slurry reaches high pressure. This preliminary gas injection allows bubbles to form and be trapped in the slurry structure before pressurization, significantly improving entrapment efficiency and reducing the volume of gas needed to achieve the desired powder density.
Solution Approach 2:
The injection point of nitrogen-rich gas is changed from the high pressure pipe (after the second pump) to the low pressure section (between the first and second pumps). This parameter change in pressure conditions during gas injection fundamentally alters the bubble formation and entrapment mechanism, leading to higher efficiency and lower gas consumption.
2Quantity of substance
If large volumes of nitrogen-rich gas are pumped into the high pressure slurry to achieve low density powder, then the powder density is reduced, but the equipment complexity and cost increase
Solution Approach 1:
Gas injection is performed in advance at low pressure conditions, where the slurry is more receptive to bubble incorporation. This preliminary action eliminates the need for complex high-pressure gas injection equipment and allows for simpler, more cost-effective system design while achieving the same low-density powder product.
3Reliability
If nitrogen-rich gas is injected at high pressure to entrap bubbles in the slurry, then bubble entrapment occurs, but the entrapment efficiency is low
Solution Approach 1:
The pressure parameter during gas injection is changed from high pressure to low pressure (between the first and second pumps). This parameter change creates optimal conditions for bubble formation and entrapment in the slurry, significantly improving entrapment efficiency while maintaining reliable bubble incorporation in the final powder product.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly improves the efficiency of nitrogen-rich gas capture, allowing for the production of low-density spray-dried detergent powder with significantly lower nitrogen-rich gas consumption, reducing costs and equipment requirements.
Implementation Method 1
The nitrogen-rich gas is mixed with the slurry to form a slurry containing nitrogen-rich gas bubbles. Thus, the nitrogen-rich gas bubbles are dispersed in the high pressure slurry
Implementation Method 2
the nitrogen-rich gas bubbles are dispersed in the high pressure slurry and trapped within the spray-dried slurry droplets during drying and subsequently trapped in the spray-dried powder
Implementation Method 3
spraying the mixture through the spray nozzle into a spray-drying tower; and spray-drying the mixture to form a spray-dried powder
Data Source
AI summary
The present invention is to a process for preparing a spray-dried detergent powder comprising: (a) forming an aqueous detergent slurry in a mixer; (b) transferring the aqueous detergent slurry from the mixer to a pipe leading through a first pump and then through a second pump to a spray nozzle; (c) contacting a liquid detergent ingredient having a viscosity of less than 2 Pa.s to the aqueous detergent slurry in the pipe after the first pump and before the second pump to form a mixture; (d) spraying the mixture through the spray nozzle into a spray-drying tower; and (e) spray-drying the mixture to form a spray-dried powder, wherein a nitrogen-rich gas is introduced between the first and second pumps.